Firms work to cut car weight

[atlaw4u]

Manufacturing process is key, analysts say

Karl Henkel - DETROITNEWS - October 25, 2012

As automakers prepare to meet strict fuel-efficiency standards, some have already ditched ashtrays, CD players and spare tires to reduce weight.

But the body, which makes up most of a typical car's weight, will be the area where automakers will have to shed the most poundage if they want to meet upcoming Corporate Average Fuel Economy standards.

Some automakers have turned to materials like aluminum, which is considerably lighter but more expensive than steel. Thirty percent of the industry's automobile hoods are now made of aluminum.

But most buyers won't notice how automakers are trimming pounds by changing the processes in which parts are made. But Ford Motor Co., for instance, is the first automaker to use an advanced form of stamping known as hydroforming on the steel structural pillars of its new 2013 Fusion. The process sheds 18 pounds from each car.

Analysts say manufacturing processes will play an important role in weight reduction in coming years, but few automakers have changed those processes so far...[Read More]

[Indigo]

One overlooked aspect of fuel economy is the weight of the user. I see a LOT of Americans that are 100-200 pounds overweight. When they travel with their morbidly obese families in their huge SUVs (1.2 miles down to the Burger King instead of walking), I have to wonder how much the fuel economy is being cut.

Just to compare, what would the fuel economy for a compact SUV like the Ford Escape be in the following two situations? What would the effect of Family "B" be on a Prius or Insight?

-- Responsible Family "A"
Dad (195 pounds), mom (120 pounds), teenage son (140 pounds), sub-teen daughter (80 pounds).

-- Irresponsible Family "B"
Dad (350 pounds), mom (290 pounds), teenage son (270 pounds), sub-teen daughter (180 pounds).

[herm]

and all that extra food they eat and excrete is just wonderful for the planet.. Obama* should tough up and impose strict standards and penalties while he has a chance, perfect for his last few days in January.

I had Sketti for dinner last night, its a Georgia redneck recipe for spaghetti.. basically half butter and half ketchup. Yummi!, straight from the Honey Boo Boo show.. for some reason all my redneck friends hate that show.


* just some free political advice.. I see a lot of obesity that runs in families, both parents and all the kids.. it must be a genetic thing or mom just knows how to cook good!

[TheStepChild]

So am I less than responsible at 185

[herm]

you have a large truck

[wick1ert]

Originally Posted by herm

and all that extra food they eat and excrete is just wonderful for the planet.. Obama* should tough up and impose strict standards and penalties while he has a chance, perfect for his last few days in January.

I had Sketti for dinner last night, its a Georgia redneck recipe for spaghetti.. basically half butter and half ketchup. Yummi!, straight from the Honey Boo Boo show.. for some reason all my redneck friends hate that show.


* just some free political advice.. I see a lot of obesity that runs in families, both parents and all the kids.. it must be a genetic thing or mom just knows how to cook good!

These days, most moms probably don't cook anymore. Or their version of cooking isn't the same as when I grew up or you grew up. I think a lot of it comes to do with the type and amount of food that is consumed along with the lack of physical movement in today's world. And once they add those pounds on, it becomes a lack of motivation to try to change it. Why work hard to become part of the masses, when you could continue your ways, and get perks for it (first boarding on airplanes, handicap tags so you can park close, etc).

[Mendel Leisk]

How do stamped steel rims compare to alloy for weight? Neck and neck?

[sam919]

"Ford Motor Co., for instance, is the first automaker to use an advanced form of stamping known as hydroforming on the steel structural pillars of its new 2013 Fusion."

Wow... what a grossly incorrect claim! The frame rails on my 2002 Corvette Z06 are hydroformed, and GM started using the process quite a while before then. See: http://www.digitalcorvettes.com/foru...p/t-10576.html

Some quotes from that 2004 post:
"No automaker uses or manufacturers more hydroformed components than GM," said Charles Bruggemann, engineer and chief hydroforming expert with GM's body engineering center in Pontiac, Mich. "GM was the first OEM with hydroformed frame rails for cars, trucks and SUVs, and it has the most applications on the road today." While drivers can't see hydroforming's advantages, they most certainly can feel them. Hydroformed frame rails increase a vehicle's strength and stiffness, resulting in better structural integrity, ride and handling.

"In 1997, the fifth-generation Corvette represented the first true breakthrough in automotive hydroforming technology with industry-first twin seamless hydroformed frame rails."

"...hydroformed components are a lot more common than one might expect. GM began with the instrument panel beam on the 1994 Buick Regal and Oldsmobile Cutlass, and engine cradles for the 1995 Oldsmobile Aurora and Buick Riviera soon followed."

[RedylC94]

Originally Posted by sam919

"Ford Motor Co., for instance, is the first automaker to use an advanced form of stamping known as hydroforming on the steel structural pillars of its new 2013 Fusion."

Wow... what a grossly incorrect claim! The frame rails on my 2002 Corvette Z06 are hydroformed ..."

That was a deviously ambiguous sentence. Of course Ford wasn't first to use hydroforming, but they were first to use it to form pillars of a 2013 Fusion. Very tricky!

[jeffdavis]

Obviously Ford wasn't first in hydroforming, but might it be first in using hydroforming for structural pillars? I guess they're talking about the A-post, B-post, C-post, etc.